Alloy for Mud Motor Shaft Applications with High Strength, High Impact Toughness and Excellent Fatigue Life

ABSTRACT

A steel alloy is disclosed that provides a unique combination of strength, toughness, and fatigue life. The steel alloy has the following composition in weight percent:Cabout 0.15 to about 0.30Mnabout 1.7 to about 2.3Siabout 0.7 to about 1.1Crabout 1.85 to about 2.35Niabout 0.5 to about 0.9Mo + ½Wabout 0.1 to about 0.3Cuabout 0.3 to about 0.7V + 5/9 × Nbabout 0.2 to about 0.5The balance of the alloy is iron, usual impurities, and residual amounts of other elements added during melting for deoxidizing and/or desulfurizing the alloy. A hardened and tempered steel article made from the alloy is also disclosed.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of U.S. Nonprovisional patentapplication Ser. No. 16/363,400, filed Mar. 25, 2019 which is aContinuation of U.S. Nonprovisional patent application Ser. No.15/278,125, filed Sep. 28, 2016 which claims the benefit of U.S.Provisional Patent Application No. 62/233,609, filed Sep. 28, 2015, theentireties of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION FIELD OF THE INVENTION

This invention relates generally to a steel alloy that provides a uniquecombination of strength, toughness, and fatigue life. More particularly,the invention relates to a useful article made from the steel as well asa method of making the article.

DESCRIPTION OF THE RELATED ART

Directional drilling of oil wells often require the use of mud motors. Amud motor (or drilling motor) is a progressive cavity positivedisplacement pump (PCPD) placed in the drill string to provideadditional power to the bit while drilling. The PCPD pump uses drillingfluid (commonly referred to as drilling mud, or just mud) to createeccentric motion in the power section of the motor which is transferredas concentric power to the drill bit by way of the mud motor shaft and aconstant velocity joint. Because the drill bit encounters deposits ofvarying hardness and strength during the drilling operation, thetransfer of the eccentric motion as concentric power through the shaftrequires a strong shaft material that has high impact toughness as wellas good rotating bending fatigue life. The current material of choice isthe 4330V alloy that has been known to provide a yield strength (Y.S) ofabout 150 ksi (1,034 MPa) and a Charpy V-notch impact energy (CVN IE) ofabout 40 ft-lbs. (54.2 J) at room temperature.

Up until recently the 4330V shaft material has been acceptable. Now withdrilling of deeper wells into different deposits, such as shale, a needhas arisen for a stronger shaft material with better toughness thanprovided by the 4330V alloy.

SUMMARY OF THE INVENTION

The need described above is realized to a large degree by an alloyaccording to the present invention. In accordance with one aspect of thepresent invention, there is provided a high strength, high impacttoughness steel alloy that has the following broad and preferred weightpercent compositions.

Element Broad Intermediate Preferred C 0.15-0.30 0.18-0.27 0.21-0.24 Mn1.7-2.3 1.8-2.2 1.95-205 Si 0.7-1.1 0.8-1.0 0.85-0.95 Cr 1.85-2.351.95-2.25 2.05-2.15 Ni 0.5-0.9 0.6-0.8 0.65-0.75 Mo + ½W 0.1-0.30.15-0.25 0.18-0.22 Cu 0.3-0.7 0.4-0.6 0.45-0.55 V + 5/9 × Nb 0.2-0.50.25-0.45 0.30-0.40 Fe Balance Balance BalanceIncluded in the balance are the usual impurities found in commercialgrades of steel alloys produced for similar use and small amounts ofother elements retained from deoxidizing and/or desulfurizing additionsduring melting.

The foregoing tabulation is provided as a convenient summary and is notintended to restrict the lower and upper values of the ranges of theindividual elements for use in combination with each other, or torestrict the ranges of the elements for use solely in combination witheach other. Thus, one or more of the ranges can be used with one or moreof the other ranges for the remaining elements. In addition, a minimumor maximum for an element of a broad or preferred composition can beused with the minimum or maximum for the same element in anotherpreferred or intermediate composition. Here and throughout thisspecification the term “percent” or the symbol “%” means percent byweight or mass percent, unless otherwise specified.

The alloy according to the present invention provides a room temperatureY.S. of at least about 180 ksi in combination with a room temperatureCVN IE of at least about 25 ft-lbs. The alloy is also capable ofproviding a room temperature CVN IE of up to about 60 ft-lbs (81.3 J)which represents an increase of 20% in Y.S. and 50% in CVN IE comparedto the 4330V alloy. The alloy of this invention also provides very goodfatigue life as represented by a rotating bending fatigue run-out stressof 90 ksi at 10 million cycles.

In accordance with another aspect of the present invention, there isprovided a hardened and tempered steel alloy article that has a novelcombination of Y.S., CVN IE, and fatigue life. In a preferredembodiment, the article comprises a transmission drive unit for a mudmotor. The transmission drive unit includes a shaft and a constantvelocity joint. The article is formed from an alloy having any of thebroad, intermediate, or preferred weight percent compositions set forthabove. The article according to this aspect of the invention is furthercharacterized by being hardened and then tempered at a temperature ofabout 400° F. to 600° F. Alternatively, the article can be austemperedto provide other combinations of Y.S. and CVN IE for applications thatdo not require a yield strength of at least 180 ksi.

In accordance with a further aspect of the present invention there isprovided a method of making a transmission drive unit for a positivedisplacement drilling mud motor.

BRIEF DESCRIPTION OF THE DRAWINGS

The following Detailed Description will be better understood when readin connection with the drawings, wherein:

FIG. 1 is a schematic view of a mud motor and drill bit used in asubterranean drilling string (derived from Graber, K. K., Pollard, E.,Jonasson, B., and Schulte, E. (Eds.), 2002. Overview of Ocean DrillingProgram Engineering Tools and Hardware. ODP Tech. Note 31.doi:10.2973/odp.tn.31.2002);

FIG. 2 is a graph of Charpy V-notch impact energy as a function of testtemperature for the data presented in Table IV; and

FIG. 3 is a S-N graph of applied stress as a function of the number ofcycles to fracture for the R. R. Moore rotating bending fatigue datapresented in Table V.

DETAILED DESCRIPTION

The alloy according to the present invention contains at least about0.15%, better yet at least 0.18%, and preferably at least about 0.21%carbon. Carbon contributes to the strength and hardness capabilityprovided by the alloy. Carbon is also beneficial to the temperresistance of this alloy, Too much carbon adversely affects thetoughness provided by the alloy. Therefore, carbon is restricted to notmore than about 0.30% and better vet to not more than about 0.27%.Preferably, the alloy contains not more than about 0.24% carbon for goodtoughness at higher strength and hardness levels.

At least about 1.7%, better yet at least about 1.8%, and preferably atleast about 1.95% manganese is present in this alloy primarily todeoxidize the alloy. It has been found that manganese also benefits thehigh strength and toughness provided by the alloy. If too much manganeseis present, then an undesirable amount of retained austenite may resultduring hardening and quenching such that the high strength provided bythe alloy is adversely affected. Therefore, the alloy may contain up toabout 2.3% or 2.2% manganese. Preferably, the alloy contains not morethan about 2.05% manganese.

Silicon benefits the hardenability and temper resistance of this alloy.Therefore, the alloy contains at least about 0.7% silicon, better stillat least about 0.8%, silicon, and preferably, at least about 0.85%silicon. Too much silicon adversely affects the hardness, strength, andductility of the alloy. In order to avoid such adverse effects siliconis restricted to not more than about 1.1%, better yet to not more thanabout 1.0%, and preferably to not more than about 0.95% in this alloy.

The alloy according to this invention contains at east about 1.85%chromium because chromium contributes to the good hardenability, highstrength, and temper resistance provided by the alloy. Preferably, thealloy contains at least about 1.95% and better yet at least about 2.05%chromium. More than about 2.35% chromium in the alloy adversely affectsthe impact toughness and ductility provided by the alloy. Preferably,chromium is restricted to not more than about 2.25% and for bestresults, to not more than about 2.15% in this alloy.

Nickel is beneficial to the good toughness provided by the alloyaccording to this invention. Therefore, the alloy contains at leastabout 0.5% nickel and better yet, at least about 0.6% nickel. Preferablythe alloy contains at least about 0.65% nickel. The benefit provided bylarger amounts of nickel adversely affects the cost of the alloy withoutproviding a significant advantage. In order to limit the upside cost ofthe alloy, the alloy contains not more than about 0.9%, better yet tonot more than about 0.8%, and preferably to not more than about 0.75%nickel.

Molybdenum is a carbide former that is beneficial to the temperresistance provided by this alloy. The presence of molybdenum boosts thetempering temperature of the alloy such that a secondary hardeningeffect is achieved when the alloy is tempered at about 450° F. to 600°F. Molybdenum also contributes to the strength and impact toughnessprovided by the alloy. The benefits provided by molybdenum are realizedwhen the alloy contains at least about 0.1% molybdenum, better yet, atleast about 0.15%, and preferably at least about 0.18% molybdenum. Likenickel, molybdenum does not provide an increasing advantage inproperties relative to the significant additional cost of larger amountsof molybdenum. For that reason, the alloy contains not more than about0.3% molybdenum, better yet not more than about 0.25% molybdenum,preferably not more than about 0.22% molybdenum. Tungsten may besubstituted for some or all of the molybdenum in this alloy. Whenpresent, tungsten is substituted for molybdenum on a 2:1 basis.

This alloy contains at least about 0.30% copper which contributes to thehardenability and impact toughness of the alloy. The alloy may containat least about 0.4% copper and preferably contains at least about 0.45%copper. Too much copper can result in precipitation of an undesirableamount of free copper in the alloy matrix which can adversely affect thetoughness of the alloy. Therefore, not more than about 0.7%, better yet,not more than about 0.6%, and preferably not more than about 0.55%copper is present in this alloy.

Vanadium contributes to the high strength and good hardenabilityprovided by this all Vanadium is also a carbide former and promotes theformation of carbides that help provide grain refinement in the alloy.The vanadium carbides also benefit the temper resistance and secondaryhardening capability of the alloy. For those reasons, the alloypreferably contains at least about 0.20% vanadium. The alloy may containat least about 0.25% vanadium and preferably contains at least about0.30% vanadium. Too much vanadium adversely affects the strength of thealloy because of the formation of larger amounts of carbides in thealloy which depletes carbon from the alloy matrix material. Accordingly,the alloy may contain not more than about 0.5% vanadium and better yet,not more than about 0.45% vanadium. Preferably the alloy contains notmore than about 0.40% vanadium. Niobium can be substituted all of thevanadium in this alloy because like vanadium, niobium combines withcarbon to form M₄C₃ carbides that benefit the temper resistance andhardenability of the alloy. When present, niobium is substituted forvanadium on 1.8:1 basis.

This alloy may also contain a residual amount of calcium, up to about0.05%, which is retained from additions during melting of the alloy tohelp remove sulfur and thereby benefit the impact toughness provided bythe alloy. Preferably, the alloy contains not more than about 0.02% or0.01% calcium, and may contain as little as 0.005% calcium.

A small amount of titanium may be present at a residual level of up toabout 0.05% from deoxidation additions during melting. However, thealloy preferably contains not more than about 0.025% or not more thanabout 0.01% titanium. Up to about 0.05% aluminum may also be present inthe alloy from deoxidation additions during melting. Preferably, thealloy contains not more than about 0.025% or not more than about 0.015%aluminum.

The balance of the alloy is essentially iron and the usual impuritiesfound in commercial grades of similar alloys and steels. In this regard,the alloy may contain up to about 0.025% phosphorus. Preferably, thealloy contains not more than about 0.01%, and better yet, not more thanabout 0.005% phosphorus. Up to about 0.025% sulfur may also be presentin the alloy. Preferably the alloy contains not more than about 0.001%,and better yet, not more than about 0.0005% sulfur. Cobalt is alsoconsidered an impurity in this alloy. However, the alloy may contain upto about 0.25% cobalt. Preferably the alloy contains not more than about0.05% or not more than about 0.02 or 0.01% cobalt.

The alloy according to the present invention is balanced to provide highyield strength and impact toughness in the hardened and temperedcondition. In this regard, the preferred composition is balanced toprovide a yield strength of at least about 180 ksi in combination withgood toughness as indicated by a Charpy V-notch impact energy of atleast about 25 ft-lbs and up to about 60 ft-lbs and higher at roomtemperature.

Primary melting and casting of the alloy are preferably accomplishedwith vacuum induction melting (VIM). When desired, as for criticalapplications, the alloy can be refined using vacuum arc remelting (VAR).Primary melting may also be performed by arc melting in air (ARC) or ina basic oxygen furnace (BOF), if desired. After melting, the alloy maybe refined by electroslag remelting (ESR) or VAR. In addition, the alloycan be produced by using powder metallurgy techniques.

The alloy of this invention is preferably hot worked from a temperatureof up to about 2100° F. and preferably at about 1800° F. to form anintermediate product form, in particular, elongated forms such asbillets and bars. The alloy can be heat treated by austenitizing atabout 1585° F. to about 1735° F., preferably at about 1635-1660° F., forabout 1-2 hours. The alloy is then air cooled or oil quenched from theaustenitizing temperature. When desired, the alloy can be vacuum heattreated and gas quenched. The alloy is preferably tempered at about450-550° F. for about 2-3 hours and then air cooled. The alloy may betempered at up to 600° F. when lower strength can be accepted.

The alloy of the present invention is useful in a wide range ofapplications principally transmission drive shafts and constant velocityjoints used in mud motors for subterranean drilling strings. Anembodiment of a mud motor device 10 is shown in FIG. 1. The mud motordevice 10 includes a PCPD pump section 12. The PCPD pump sectionincludes a rotor 14 disposed for rotation inside a stator 16 in theknown manner. A power transmission section 18 is connected to the drillbit side of the PCPD pump rotor. The power transmission section includesa drive shaft 20 that is connected at one end to the PCPD pump and atthe other end to the drill bit 22. A bearing assembly 24 may beinterposed around the drive shaft 20. The drive shaft 20 is connected tothe PCPD pump rotor 14 and to the drill bit 22 with constant velocityjoints in the known manner. The drive shaft 20 and the constant velocityjoints are subject to significant stresses when the drill bit encountersvery hard deposits in the drilling terrain. In order to withstand suchstresses and resist deformation, the drive shaft and the constantvelocity are manufactured from the steel alloy described above.

The mud motor drive shaft according to the present invention is formedfrom an intermediate product form of the alloy, preferably round bar orrod. The intermediate form is machined to the desired diameter size andthen straightened if necessary. The machined forms are then cut to theappropriate length for the drive shaft of the transmission section of amud motor. The shafts are then hardened and tempered as described above.

It is contemplated that the alloy of this invention may also be usefulfor other drilling components including flex shafts, drilling jarmandrels, shock tools, and other downhole tools that require acombination of high yield strength and good impact toughness.

WORKING EXAMPLES

In order to demonstrate the combination of properties provided by thealloy of this invention two 35-lb. VIM heats were melted and cast. Theheats were forged into 0.625-in. sq. bars and then processed intostandard longitudinal tensile, standard long-transverse (L-T) CVNimpact, standard longitudinal fatigue specimens, and standard cubes forRockwell hardness testing. Table I contains the VIM final chemicalanalyses in weight percent for the two experimental heats.

TABLE I Heat No. C Mn Si P S Cr Ni Mo Cu V Ti Al Fe 2647 0.22 2.03 0.89<0.005 <0.001 2.10 0.68 0.21 0.50 0.35 <0.001 0.01 Bal. 2648 0.22 2.040.87 <0.005 <0.001 2.10 0.68 0.21 0.50 0.35 <0.001 0.01 Bal.

A heat treating study was performed on test samples taken from Heat No.2647. Duplicate tensile and duplicate CVN IE specimens were preparedfrom the alloy ingot and given the nine heat treatments (H.T.) shown inTable II below. The test samples were austenitized in a fluidized bedfurnace for 1.5 hours at the indicated temperatures. The test specimenswere then quenched in oil from the austenitizing temperature to roomtemperature, tempered for 2 hours at the indicated temperatures, andthen air cooled from the tempering temperature to room temperature. Theresults shown in Table II include the 0.2% offset yield strength (Y.S.)and the ultimate tensile strength (U.T.S.) in ksi, the percentelongation (% El.), the percent reduction is area (% R.A.), the CharpyV-notch impact energy (CVN) in foot-pounds, and the average RockwellC-Scale hardness (HRC) for each sample tested. The average tensile andCVN properties for each heat treatment are also reported. CVN IE testingwas performed in accordance with ASTM Standard Test Procedure E23-12C.

TABLE II Austenitizing Tempering Sample H.T. Temperature Temperature No.Y.S. U.T.S. % El. % R.A. CVN HRC A 1635° F. 450° F. 1 176.3 219.6 16.062.3 66.4 2 184.3 222.5 16.4 60.4 72.8 Avg. 180.3 221.1 16.2 61.3 69.645.5 B 1635° F. 500° F. 1 188.6 223.0 13.7 58.8 65.8 2 184.8 223.0 14.659.3 74.6 Avg. 186.7 223.0 14.1 59.0 70.2 45.0 C 1635° F. 550° F. 1188.8 223.2 15.0 60.8 67.6 2 188.8 223.2 15.0 60.8 71.1 Avg. 188.8 223.215.0 60.8 69.4 44.7 D 1660° F. 450° F. 1 184.6 226.3 15.2 60.8 70.3 2180.6 222.9 15.3 60.3 71.1 Avg. 182.6 224.6 15.2 60.6 70.7 45.5 E 1660°F. 500° F. 1 185.4 223.8 15.2 60.2 70.3 2 185.1 223.4 14.3 57.7 71.5Avg. 185.2 223.6 14.7 58.9 70.9 45.6 F 1660° F. 550° F. 1 181.0 223.414.6 59.7 64.7 2 184.8 223.0 14.3 56.7 64.7 Avg. 182.9 223.2 14.4 58.264.7 45.7 G 1685° F. 450° F. 1 177.9 223.2 13.7 58.7 73.7 2 174.1 222.314.8 60.7 73.9 Avg. 176.0 222.7 14.2 59.7 73.8 45.7 H 1685° F. 500° F. 1180.6 222.9 13.3 58.3 72.5 2 177.0 223.1 14.3 61.3 73.6 Avg. 178.8 223.013.8 59.8 73.1 43.4 I 1685° F. 550° F. 1 180.9 223.2 14.3 61.8 68.0 2180.6 222.9 13.6 57.8 71.9 Avg. 180.7 223.0 14.0 59.8 70.0 45.2

An important consideration for any high strength steel is whether itexhibits a Ductile-to-Brittle Transition Temperature (DBTT). Since oiland gas drilling can be performed in geographical areas that vary widelyin temperature, the DBTT of the alloy for the mud motor transmissionshaft is particularly of that application. Therefore, additional CVNsamples from Heats 2647 and 2648 were tested to evaluate the CVN impactenergy at temperatures ranging from −40° F. to +150° F. The results areshown in Table III below including the heat number for each test sample,the test temperature in ° F. (Temp.), and the CVN IE in ft-lbs (CVN).The results are graphed in FIG. 2.

TABLE III Heat No. Temp. CYN 2648 150 68.4 2647 68 67.6 2647 68 71.12648 68 63.4 2648 68 66.5 2648 0 57.8 2648 0 59.2 2648 −20 47.9 2647 −2053.9 2647 −40 52.6 2647 −40 53.0

The data presented in Table III and FIG. 2 show that the alloy of thisinvention has essentially no ductile-to-brittle transition temperatureover the tested temperature range. This means that the good toughnessprovided by the alloy of this invention is provided over a wide range oftemperatures.

In order to demonstrate the fatigue life provided by the alloy accordingto the present invention, R.R. Moore Rotating Bending testing wasperformed on the fatigue specimens. Before testing, the fatiguespecimens were hardened and tempered using Heat Treatment C describedabove. The results of the rotating bending fatigue testing are reportedin Table IV below including the applied stress (Stress) in ksi and thenumber of cycles (Cycles) until the specimen fractured. The data aregraphed in FIG. 3.

TABLE IV Stress Cycles 110 57,000 110 213,000 100 224,000 100 2,337,00090 20,805,000 90 15,801,000

The terms and expressions which are employed in this specification areused as terms of description and not of limitation. There is nointention in the use of such terms and expressions of excluding anyequivalents of the features shown and described or portions thereof. Itis recognized that various modifications are possible within theinvention described and claimed herein.

1. A steel alloy having a unique combination of strength, toughness, andfatigue life, said alloy consisting essentially of, in weight percent, Cabout 0.15 to about 0.30 Mn about 1.7 to about 2.3 Si about 0.7 to about1.1 Cr about 1.85 to about 2.35 Ni about 0.5 to about 0.9 Mo + ½W about0.1 to about 0.3 Cu about 0.3 to about 0.7 V + 5/9 × Nb about 0.2 toabout 0.5

and the balance is iron, usual impurities, and residual amounts of otherelements added during melting for deoxidizing and/or desulfurizing thealloy.
 2. The steel alloy as claimed in claim 1 which contains at leastabout 0.18% carbon.
 3. The steel alloy as claimed in claim 1 whichcontains at least about 1.8% manganese.
 4. The steel alloy as claimed inclaim 1 which contains at least about 0.8% silicon.
 5. The steel alloyas claimed in claim 1 which contains at least about 1.95% chromium. 6.The steel alloy as claimed in claim 1 which contains at least about 0.6%nickel.
 7. The steel alloy as claimed in claim 1 which contains at leastabout 0.15% Mo+½ W.
 8. The steel alloy as claimed in claim 1 whichcontains at least about 0.25% (V+( 5/9×Nb)).
 9. The steel alloy asclaimed in claim 1 which contains not more than about 0.25% cobalt. 10.A steel alloy having a unique combination of strength, toughness, andfatigue life, said alloy consisting essentially of, in weight percent, Cabout 0.15 to about 0.27 Mn about 1.8 to about 2.2 Si about 0.8 to about1.0 Cr about 1.95 to about 2.25 Ni about 0.6 to about 0.8 Mo + ½W about0.15 to about 0.25 Cu about 0.4 to about 0.6 V + 5/9 × Nb about 0.25 toabout 0.45

and the balance is iron, usual impurities, and residual amounts of otherelements added during melting for deoxidizing and/or desulfurizing thealloy.
 11. The steel alloy as claimed in claim 10 which contains atleast about 0.21% carbon.
 12. The steel alloy as claimed in claim 10which contains at least about 1.95% manganese.
 13. The steel alloy asclaimed in claim 10 which contains at least about 0.85% silicon.
 14. Thesteel alloy as claimed in claim 10 which contains at least about 2.05%chromium.
 15. The steel alloy as claimed in claim 10 which contains atleast about 0.65% nickel.
 16. The steel alloy as claimed in claim 10which contains at least about 0.18% Mo+½ W.
 17. The steel alloy asclaimed in claim 10 which contains at least about 0.25% (V+( 5/9×Nb)).18. The steel alloy as claimed in claim 10 which contains not more thanabout 0.02% cobalt.
 19. A hardened and tempered steel article formedfrom a steel alloy consisting essentially of, in weight percent, about Cabout 0.15 to about 0.30 Mn about 1.7 to about 2.3 Si about 0.7 to about1.1 Cr about 1.85 to about 2.35 Ni about 0.5 to about 0.9 Mo + ½W about0.1 to about 0.3 Cu about 0.3 to about 0.7 V + 5/9 × Nb about 0.2 toabout 0.5

and the balance is iron, usual impurities, and residual amounts of otherelements added during melting for deoxidizing and/or desulfurizing thealloy, said article providing a yield strength of at least about 180 ksiand a Charpy V-notch impact energy of at least about 25 ft-lbs.